Electrical vehicle electrical performance test solution

The high-energy system of the new energy vehicle has the characteristics of high voltage and high current, and has potential personal risk. The primary purpose of the electrical performance test of the high-voltage system is to eliminate the risk of harm to personal safety, and to evaluate the vehicle power system, charging system and test through testing. Potential defects in the design and implementation of the power conversion system, and the identification of the best engineering solutions for the problem, so as to minimize the risk of the vehicle and the after-sales service costs.

This solution can conduct comprehensive testing services for new energy vehicles and propose rectification and optimization.

Figure 1 high-voltage system electrical performance test

EV/PHEV high voltage electrical performance test process

Figure 2 High-voltage system electrical performance test process

New energy vehicle electric performance test suit

•48VBSG model

Compared with traditional vehicles, BSG models have added BSG motors, DC/DC, 48V batteries and related wiring harnesses to the system architecture. The output characteristics of BSG motors and DC/DC require test evaluation, and matching between power systems, energy recovery strategies, and load dump pulses also requires test verification.

Figure 348VBSG power system

• EV/PHEV models

With the global energy crisis and environmental pollution becoming increasingly serious, new energy vehicles have gradually become one of the future development directions of automobiles. Conducting electrical performance testing of high-voltage systems, establishing a complete high-voltage system electrical performance testing system, early detection of design defects and rectification and optimization will greatly reduce the risks and costs in the later period.

Considering that the high-voltage system voltage of new energy vehicles exceeds the human body safety voltage, the high-voltage electrical performance test items mainly include safety-related aspects and performance matching related aspects.

Safety related: insulation resistance, potential equalization resistance, active discharge, etc.

Performance matching related: power distribution, charging performance, energy recovery verification, etc.

Figure 4EV/PHEV power system

Evaluation basis

Based on the SAE, ISO, GB and other standards and the design goals of the OEM, the evaluation of the test results and reasonable optimization recommendations are given.

New energy vehicle electrical performance test tool

The high-voltage performance test tool is based on the self-developed electrical performance test system, supplemented by high-voltage sensors, power analyzers and insulation resistance testers, etc., to meet the needs of all the above test items.

Figure 5 electrical performance test tool